Kiatmanaroj, Subongkoj (2004) Sandwich injection moulding with thermoset materials. PhD thesis, University of Warwick.

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Abstract

This project aimed to study the feasibility of making a thermoset sandwich injection
moulding from a novel thermoset co-injection moulding system. Two thermoset
polyesters, BMC and a powder coating, were used for all experiments. Flow and cure
of those materials in a newly designed manifold system were studied and some
thermoset sandwich injection mouldings have been produced. Despite producing
novel co-injection mouldings using two thermoset materials together, the results
showed that the existing system was not applicable for large-scale production of
sandwich parts and needed some improvements.
The experiments on the moulding materials and single injection of each material
gave temperature windows and settings for the co-injection moulding. The results
from all experiments indicated that temperature and the time of applying heat to a
thermoset material were very important to its flow ability and formation. Especially
when producing a sandwich moulding, adequate heat and time was necessary for the
skin material to form a sufficient layer to cover the core material. Investigation of the
sandwich moulding cross-sections showed that applying more core injection delay
time could help to increase the skin thickness. Surface assessmenitn dicated that the
surface quality was also improved when the skin layer was thicker. However, core
break-through at the position opposite to the mould gate was found in all sandwich
mouldings showing that the type of mould gate was also important. A central sprue
gated mould used in these experiments was found to be not suitable for producing a
sandwich component using this machine configuration.
A new manifold design was proposed and was compared to the existing manifold
designed by using a simulation software package from Moldflow. Thermoset single
injection moulding simulation was used to help to understand the flow and cure of a
thermoset material in both manifold designs. It was shown that the new manifold
system design was an improvement on the existing one.

Item Type:	Thesis or Dissertation (PhD)
Subjects:	T Technology > TP Chemical technology
Library of Congress Subject Headings (LCSH):	Molding (Chemical technology), Thermosetting composites, Sandwich construction
Official Date:	May 2004
Dates:	Date Event May 2004 Submitted
Institution:	University of Warwick
Theses Department:	School of Engineering
Thesis Type:	PhD
Publication Status:	Unpublished
Supervisor(s)/Advisor:	Smith, Gordon F.
Sponsors:	National Metal and Materials Technology Centre (Thailand) (MTEC) ; Thailand. Krasūang Witthayāsāt, Thēknōlōyī, læ Kānphalangngān [Ministry of Science, Technology, and Energy]
Extent:	xvii, 309 p.
Language:	eng
URI:	http://wrap.warwick.ac.uk/id/eprint/36685

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